Waterproof and explosion-proof circuit board and electronic valve actuator for flow control applications

ABSTRACT

A bulkhead passthrough connector containing a printed circuit board (PCB) for transferring electrical signals across a bulkhead to an electronic valve actuator, an electronic valve actuator configured to operate and communicate with a valve using a PCB through a bulkhead, the electronic valve actuator, and a method of assembling a bulkhead passthrough connector incorporating a PCB. The embodiments may include a passthrough partition which separates one side of the bulkhead from another. A PCB retainer may also be secured to the passthrough partition. The PCB is attached to the PCB retainer and extends from one side to another side of the bulkhead through the passthrough partition. The PCB further includes electrical paths printed on the PCB and electrical connectors located on both sides of the bulkhead to enable communication with external devices.

TECHNICAL FIELD

This present disclosure relates generally to electronic valve actuatorsand related flow control equipment, and more particularly to anelectronic valve actuator with a printed circuit board (PCB) that ispackaged with a valve actuator to provide one or both of improvedwaterproof or explosion-proof features.

BACKGROUND

Conventional electronic valve actuators comprise an electrically driveninput shaft and interact or are monitored with various sensors andinputs. Since valve actuators may be part of a system in hazardousoperating conditions, certain components of the valve actuator may belocated in a bulkhead to protect them from damage.

Bulkheads may be used in any number of applications or industries wheretwo electrical compartments are to be separated. For example, a bulkheadcan separate a customer interface compartment from an internalcompartment the latter of which the customer is not intended to enter. Abulkhead may also separate two distinct internal electrical compartmentsthat have weatherproof, flameproof, or explosion-proof capability andwhere access should be restricted. Traditional bulkheads may utilizewired connections (called passthrough connectors) to allow data transferand related communication between the two sides of the bulkhead. Thebulkhead passthrough allows for monitoring, actuation, communication,and other needed functions for the bulkhead. The passthrough connectorsalso allow for interfacing with terminal blocks that may be integratedinto the bulkhead.

However, due to the necessary size of the wires used in traditionalpassthrough connectors, there are a limited number of electrical pathsavailable to transfer signals through the bulkhead. Additionally, thepassthrough wires are present in a part of the path through the bulkheadthat requires sealing to prevent deterioration of the system. Thesecommonly used technologies require a high number of interconnects andtherefore take up additional of space that can be reduced to improve theperformance of the bulkhead. Further, the wires can cause negativeelectromagnetic compliance and compatibility issues.

Moreover, the use of traditional bulkhead passthrough connectorsutilizing wires to transmit signals typically requires the use of pouredseals for the bulkhead in order to separate the two bulkhead sides. Theprocess of creating the poured seal is cumbersome, time consuming, anddifficult. Specifically, the mixtures to form the seal must be pouredinto the space in the bulkhead with the wires in a specific order andtime must be taken to allow the mixture to harden. Additionally, themixture must be maintained at a specific temperature during this processto cure properly. This procedure is typically performed in the fieldwith limited tools, resources, and time, making the task even moredifficult.

Another type of bulkhead passthrough connector sends high frequencyradio signals, such as WiFi (Wireless Fidelity) or Bluetooth, throughthe bulkhead to facilitate communication between the two sides of thebulkhead. However, the use of high frequency radio signals to transferinformation greatly increases cost due to the expensivetelecommunication parts required.

There remains a need to provide a bulkhead passthrough connector thatreduces the space taken up in the bulkhead by the connector, removes theneed for poured seals, and reduces the cost of the connector and thecost of the installation process.

SUMMARY

In one embodiment, a bulkhead passthrough connector for transferringelectrical signals across a bulkhead to an electronic valve actuator isdisclosed. The connector may include a passthrough partition whichseparates one side from another side of the bulkhead. A PCB retainer mayalso be secured to the passthrough partition. A PCB is attached to thePCB retainer and extends from one side to another side of the bulkheadthrough the passthrough partition. The PCB can be configured to transmitelectric signals from the one side to another side of the bulkhead. ThePCB further includes paths printed on a printed circuit board andelectrical connectors located on both sides of the bulkhead to enablecommunication with external devices. The PCB may further be used withelectronic valve actuators.

In one embodiment, an electronic valve actuator configured to operateand communicate with a valve through a bulkhead, the electronic valveactuator is disclosed. The electronic valve actuator includes a motorwhich actuates the valve by a motor drive shaft, and the motor iscontrolled by a gear key encoder programed through the electricalsignals of the passthrough connectors. Bulkhead passthrough connectorsmay transfer electrical signals across each bulkhead to an electronicvalve actuator. Controlling an electronic valve actuation using a PCBmay be achieved if the PCB can interface with local control using knobs,touchscreen or rotary switches. The PCB can utilize remote controlthrough wires connected to a remotely located control using knobs,touchscreen or rotary switches. The PCB can use wireless control. ThePCB can use network control using wires or wireless input.

In one embodiment, a method of assembling a bulkhead passthroughconnector for an electronic valve actuator is disclosed. A PCB issecured within a PCB retainer, where the retainer has an aperture toaccept the PCB. The PCB is positioned in the aperture so the PCB extendsthrough the PCB retainer and the PCB retainer is secured to apassthrough partition so the PCB extends through the passthroughpartition. The assembled bulkhead passthrough connector is configured tobe secured to a bulkhead so the passthrough partition separates one sideof the bulkhead from the other to transmit signals. The bulkhead is thenattached to the electronic valve actuator so one side cooperates withthe electronic valve actuator, which allows the PCB to interface with agear key encoder. The gear key encoder controls the electronic valveactuator motor and drives a motor drive shaft to actuate the valve.

BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS

The following detailed description of the present disclosure can be bestunderstood when read in conjunction with the following drawings, wherelike structure is indicated with like reference numerals and in which:

FIG. 1 shows a cutaway view of an electronic valve actuator attached toa valve actuator control through a bulkhead which is actuated by a PCBof a PCB bulkhead assembly and a PCB within the valve actuator control,according to one aspect of the present disclosure;

FIG. 2 shows a cut-away view of one example of a valve actuator that maybe incorporated by the present disclosure;

FIG. 3 shows a top perspective view of the PCB bulkhead assemblyaccording to one aspect of the present disclosure;

FIG. 4 shows a bottom perspective view of the PCB bulkhead assembly ofFIG. 3, according to one aspect of the present disclosure;

FIG. 5 shows a cutaway view of the PCB bulkhead assembly of FIGS. 3 and5, along with a weather-proofing seal, according to one aspect of thepresent disclosure;

FIG. 6 shows a top elevation view of the PCB bulkhead assembly of FIG.5, according to one aspect of the present disclosure; and

FIG. 7 shows a bottom perspective view of the PCB bulkhead assembly ofFIG. 5 and FIG. 6 with an explosion-proof seal that may also include aweatherproof feature, according to one aspect of the present disclosure.

DETAILED DESCRIPTION

Referring initially to FIG. 1, a valve actuator control 150 coupled toan electronic valve actuator 100 through a PCB 330. The valve actuatorcontrol 150 further comprises bulkhead 200 and a PCB 330 located betweena first compartment 510 and a second compartment 520 of the valveactuator control 150. The valve actuator 100 and a bulkhead 200 areconnected to a valve (not shown) through a valve interface 190. Theactuator 100 includes circuitry formed on a PCB 330 of the bulkhead 200which communicates between valve actuator control 150 and the valveactuator 100. The PCB 330 of the valve actuator control 150 and thevalve actuator 100 are shown located within a PCB bulkhead assembly 300,which is configured to secure the PCB within the bulkhead 200.

FIG. 2 shows a valve actuator 100 which could be incorporated in atleast one embodiment according to the present disclosure. An optionalhand wheel 101 attached to a drive sleeve 102 though a hand wheeladapter 111 may be used to manually control the electronic valveactuator. The housing 104 encapsulates the motor 114 which drives amotor drive shaft 109 and an optional worm shaft 103 to engage the wormgear 110 of the drive sleeve 102 or other supplemental actuation means.The motor drive shaft 109 then actuates the valve. A declutch handle 105and a declutch mechanism 113 may also be included to engage anddisengage the drive sleeve 102 or other supplemental actuation means. Agear key encoder 106 allows the electronic valve actuator 100 to achieverepeatable control of the actuation by sensing the valve position. Thegear key encoder 106 may be included in a controller (not shown) whichprovides a means of controlling all or part of the electronic valveactuator 100. The gear key encoder 106 may be programed by one or morelogic elements, such as processors capable of executing machine readableinstructions contained within PCBs 330. The disclosed electronic valveactuator 100 of FIG. 2 also comprises a control module 108, circuitboard 105, control panel 107 and display 102, or may replace one or moreof these elements with a PCB 330 or PCB bulkhead assembly 300. Theelectronic valve actuator 100 is therefore capable of actuating a valveby receiving inputs from a PCB 330 to activate the motor 114 as requiredto actuate the valve through the motor drive shaft 109 according to thegear key encoder 106.

Referring again to FIG. 1, the use of the PCB 330 in this embodimentallows for separation of the valve actuator 100 and the valve actuatorcontrol 150 to prevent unwanted crossover interference of electronicsignals through multiple wires, a waterproof seal, and anexplosion-proof barrier. In one form shown in FIG. 1, the bulkhead 200is positioned between a first compartment 510 and a second compartment520 of the valve actuator control 150, where a customer has access tothe first compartment 510 but where the second compartment 520 isinaccessible. A portion of the valve actuator 100 or the valve actuatorcontrol 150 that is inaccessible may restrict direct or indirectphysical access or may restrict direct or indirect electrical orcommunication access. The first compartment 510 may comprise terminalblocks 600 to allow the customer to interface with the PCB 330 whichwill then communicate with the system of the second compartment 520. Thefirst compartment 510 may comprise a user interface 160 allowing accessto the valve actuator control 150 to the customer, which may simplifythe interaction with the PCB 330 and the valve actuator 100, protectedby a user access cover 165. In another form, shown in FIG. 1, thebulkhead 200 is positioned between the second compartment 520 of thevalve actuator control 150 and a third compartment 530 of the valveactuator 100. In this embodiment the customer has access to neithercompartment and the PCB 330 communicates between the valve actuator 100and the valve actuator control 150. These embodiments are contemplatedto allow for the use of waterproof or explosion-proof seals.

Referring next to FIGS. 3 and 4, a PCB bulkhead assembly 300 accordingto a first aspect of the present disclosure includes a bulkheadpassthrough connector in the form of a passthrough partition 310, PCBretainer 320, and PCB 330. In one configuration, the passthroughpartition 310 is designed to be fitted securely within the spaceseparating the two sides of a bulkhead (not shown). Additionally, thepassthrough partition 310 is contemplated to engage and secure the PCBretainer 320. The PCB retainer 320, secured to the passthrough partition310, maintains an aperture 325 defined within the PCB retainer 320 tocooperate and retain the PCB 330. The PCB retainer 320 may include twoor more separate sections to allow for ease of installation and securingto the passthrough partition 310. The use of more than one section forthe PCB retainer 320 allows for simplified installation in thepassthrough partition 310 as well as a simplified connection between thePCB retainer 320 and the PCB 330. Finally, the PCB 330 is coupled to thePCB retainer 320 as it extends from one side of the bulkhead to theother, allowing for communication of the signals sent through the PCB330 between the separate sides of the bulkhead.

In certain embodiments, a bulkhead 200 can separate a user interfacecompartment from an internal compartment the customer is not intended toenter. A bulkhead 200 may also separate two distinct internal electricalcompartments that have weatherproof, flameproof, or explosion-proofcapability and where access should be restricted. Bulkheads 200encompass passthrough connectors which facilitate data transfer betweenthe two sides of the bulkhead 200. The bulkhead passthrough allows formonitoring, actuation, communication, and other needed functions for thebulkhead 200. The passthrough connectors also allow for interfacing withterminal blocks 600 that may be integrated into the bulkhead 200.

Regarding the PCB 330, the removal of wires to transmit signals allowsfor creating a customizable combination of one or more power, analog,digital, and radio frequency (RF) signals to pass through a commonbulkhead design. The PCB 330 is contemplated to include electrical pathsas a set of internal solder traces, in place of the traditional wiredbulkhead passthrough connectors. The use of a PCB 330 allows for a morecompact and efficient design with a larger number of electrical pathsthan previously possible. The PCB 330 may be designed as a multi-layerdesign with multiple signal traces. Some of the connections possiblewith the PCB 330 include power, control, power lead, power for analternating current (AC) and direct current (DC) actuator, analogconnections to disclose the position of one or more valves, input andoutput, antenna connections, or the like. In at least one embodiment, avertical orientation of the PCB 330, along axis z of FIG. 3, minimizesbulkhead area to allow a maximum number of electrical signals and powerto pass through an explosion-proof and waterproof barrier whileminimizing the bulkhead surface area of the assembly. Theseconfigurations allow the passthrough to be used in high pressurecontainment applications in order to reduce the likelihood of leakage.Additionally, while an explosion-proof or waterproof seal may be used,applications requiring a weather-proof seal may also be used as aplatform for the PCB bulkhead assembly 300 and the PCB 330.

In another embodiment, applying industry standard PCB layout techniques,such as RF strip-line and micro-strip, to the PCB 330 allow for anincreased number of circuits on the PCB 330 and remove the need forbulkier communication means. The present embodiments using the PCB 330allow for an air tight seal where traditional stranded wires bundledwithin an insulator in a wired design have a leak path present.

Additionally, the PCB 330 may be designed with traditional circuit-aideddesign (CAD) techniques to also include PCB mounted connectors andelectronic circuitry on both sides of the sealed bulkhead. The use ofthese techniques eliminates the need for wire cable harnesses to andfrom traditional bulkhead passthrough connectors. The use of a PCB 330built with this technology allows for compact designs, reduces cost, andprevents unwanted radiated electromagnetic interference. The PCB 330 mayalso include custom circuit layouts which can be configured to providecommunication needs required by any specific bulkhead design.

A PCB bulkhead assembly 300 allows for board-to-board connections on theservice side of the assembly 300, which would not be possible using thetraditional wired bulkhead passthrough connectors. It is contemplatedthat one or more embodiments of the assembly 300 may includeboard-to-board connections on the PCB 330. Likewise on the customer sideof the assembly 300, the terminal blocks 600 (FIG. 1) for interface maybe soldered to the PCB 330. The terminal block 600 allows for theinterface between third-part equipment and the PCB 330 usingstandardized connections. Further, the use of a PCB bulkhead assembly300 allows for the use of weather-proof conduit seals and eliminates theneed to seal the conduits with an explosion-proof or flameproof seal,although they may still be used in conjunction with the assembly 300.

Referring finally to FIGS. 5 through 7, a PCB bulkhead assembly 300 mayinclude seals to ensure the continued performance of the bulkhead andallow the two sides of the bulkhead to remain isolated from each otherduring operation. Specifically, as shown in FIG. 6 the assembly 300further includes a sealant 350 between at least the PCB retainer 320,the passthrough partition 310, and the PCB 330, which may be designed toform a weatherproof seal. As shown in FIG. 7, the PCB bulkhead assembly300 may further include an epoxy 360, which may be designed to form anexplosion-proof seal. The assembly 300 may also include fasteners 340which secure the PCB retainer 320 to the passthrough partition 310. Thefasteners 340 may be any suitable means for securing, such as bolts,screws, pins, and clamps or any other suitable means, and further may bereleased to allow the PCB retainer 320 to be removed from thepassthrough partition 310. It may be desirable to remove the PCBretainer 320 so the PCB 330 can be serviced or removed from the assembly300.

In at least one embodiment, the PCB bulkhead assembly 300 communicateswith the electronic valve actuator 100. Other types of equipment thatcan be controlled with the PCB 330 include pumps and valve positioners.The PCB 330 may interface with local control using knobs, touchscreen orrotary switches. The PCB 330 may utilize remote control through wiresconnected to a remotely located control using knobs, touchscreen orrotary switches. The PCB may be controlled by wireless control. Finally,in another embodiment the PCB may utilize network control using wired orwireless inputs.

A PCB bulkhead assembly 300 may be assembled and ready for use withsignificantly less effort than a traditional bulkhead assembly. Onemethod of assembly a PCB bulkhead assembly 300 as described herein is tofirst secure a PCB 330 within one or more sections of a PCB retainer320. The PCB retainer 320 may include an aperture 325 which is shaped toaccept the PCB 330, and is defined within the PCB retainer 320. The PCB330 extends through the PCB retainer 320 in order to allow communicationbetween the two sides of the bulkhead. The PCB retainer 320 is securedto the passthrough partition 310. The PCB retainer 320 can be secured tothe passthrough partition 310 with the use of fasteners 340 or any othersuitable means. Furthermore, the fasteners 340 may be releasable inorder to allow the PCB retainer 320 to be separated from the passthroughpartition 310. The passthrough partition 310 is then placed within thebulkhead where the passthrough partition 310 separates the two sides ofthe bulkhead and the PCB 330 allows electrical signals to pass from oneside of the bulkhead to the other, and secured to the bulkhead.Additionally, a sealant 350 may be applied to the assembly 300 to form aweather-proof seal while an epoxy 360 may be applied to the assembly 300to form an explosion-proof seal.

It is noted that terms like “preferably”, “generally” and “typically”are not utilized herein to limit the scope of the claimed embodiments orto imply that certain features are critical, essential, or evenimportant to the structure or function of the claimed embodiments.Rather, these terms are merely intended to highlight alternative oradditional features that may or may not be utilized in a particularembodiment of the present disclosure. Likewise, for the purposes ofdescribing and defining the present disclosure, it is noted that theterms “substantially” and “approximately” and their variants areutilized herein to represent the inherent degree of uncertainty that maybe attributed to any quantitative comparison, value, measurement orother representation, as well as to represent the degree by which aquantitative representation may vary without resulting in a change inthe basic function of the subject matter at issue.

While certain representative embodiments and details have been shown forpurposes of illustrating the disclosure, it will be apparent to thoseskilled in the art that various changes may be made without departingfrom the scope of the disclosure, which is defined in the appendedclaims.

What is claimed is:
 1. A bulkhead passthrough connector for transferringelectrical signals across a bulkhead to an electronic valve actuator,the connector comprising: a passthrough partition separating a firstside of the bulkhead and a second side of the bulkhead; a printedcircuit board retainer secured to the passthrough partition; and aprinted circuit board secured to the printed circuit board retainer andextending from the first side of the bulkhead to the second side of thebulkhead through the passthrough partition, the printed circuit boardbeing configured to transmit electric signals from between the firstside of the bulkhead and the second side of the bulkhead, the printedcircuit board comprises electrical paths printed thereon and electricalconnectors located at the first side of the bulkhead and the second sideof the bulkhead configured to enable communication with externaldevices.
 2. The bulkhead passthrough connector of claim 1, wherein theprinted circuit board retainer maintains an aperture to cooperate andretain the printed circuit board.
 3. The bulkhead passthrough connectorof claim 1, wherein the printed circuit board retainer is comprised of aone or more separate sections joined together to secure the printedcircuit board.
 4. The bulkhead passthrough connector of claim 1, whereinthe printed circuit board is a multi-layer circuit with multiple signaltraces.
 5. The bulkhead passthrough connector of claim 1, wherein theelectrical connectors of the printed circuit board includes at least oneof power, control, power lead, power for an ac actuator, power for a dcactuator, analog connections to disclose valve position, input andoutput, and antenna connections.
 6. The bulkhead passthrough connectorof claim 1, wherein the printed circuit board further comprises traceswith RF strip-line and micro-strip printed circuit board layout.
 7. Thebulkhead passthrough connector of claim 1, wherein the printed circuitboard further comprises printed circuit board mounted connectors on atleast one side of the bulkhead.
 8. The bulkhead passthrough connector ofclaim 1, wherein the printed circuit board further comprisesboard-to-board connections on at least one side of the bulkhead.
 9. Thebulkhead passthrough connector of claim 1, wherein the printed circuitboard further comprises terminal blocks directly connected to theprinted circuit board on at least one side of the bulkhead.
 10. Thebulkhead passthrough connector of claim 1, further comprising aweather-proof conduit seal between the printed circuit board retainerand the printed circuit board or the passthrough partition.
 11. Thebulkhead passthrough connector of claim 1, further comprising anexplosion-proof seal between the printed circuit board retainer and theprinted circuit board or the passthrough partition.
 12. The bulkheadpassthrough connector of claim 1, further comprising fasteners whichsecure the printed circuit board retainer to the passthrough partition.13. The bulkhead passthrough connector of claim 12, wherein thefasteners releasably secure the printed circuit board retainer to thepassthrough partition.
 14. The bulkhead passthrough connector of claim1, wherein the printed circuit board transmits signals to one or moreactuators, pumps and/or valve positioners.
 15. The bulkhead passthroughconnector of claim 14, wherein the bulkhead is positioned between avalve and a valve actuator and the printed circuit board communicatesbetween the valve and the valve actuator.
 16. The bulkhead passthroughconnector of claim 1, wherein the printed circuit board is controlled bylocal control, wired remote controls, wireless controls, wired networkinputs, and/or wireless network inputs.
 17. An electronic valve actuatorconfigured to operate and communicate with a valve through a bulkhead,the electronic valve actuator comprising: a controller comprising a gearkey encoder; a motor configured to actuate the valve through a motordrive shaft, the motor being controlled by the gear key encoder; one ormore bulkhead passthrough connectors for transferring electrical signalsacross each bulkhead to an electronic valve actuator, the connectorcomprising: a passthrough partition separating a first side of thebulkhead and a second side of the bulkhead; a printed circuit boardretainer secured to the passthrough partition a printed circuit boardsecured to the printed circuit board retainer and extending from thefirst side of the bulkhead to the second side of the bulkhead throughthe passthrough partition, the printed circuit board being configured totransmit electric signals from between the first side of the bulkheadand the second side of the bulkhead, the printed circuit board compriseselectrical paths printed thereon and electrical connectors located atthe first side of the bulkhead and the second side of the bulkheadconfigured to enable communication with external devices.
 18. Theelectronic valve actuator of claim 17, wherein the bulkhead ispositioned between a two compartments, where one compartment isaccessible and one compartment is inaccessible.
 19. The electronic valveactuator of claim 17, wherein the bulkhead is positioned between twocompartments, where both compartment are inaccessible.
 20. A method ofassembling a bulkhead passthrough connector for an electronic valveactuator, the method comprising: securing a printed circuit board withinat least one section of a printed circuit board retainer, the printedcircuit board retainer forming an aperture defined to accept the printedcircuit board; positioning the printed circuit board in the aperture sothe printed circuit board extends through the printed circuit boardretainer; securing the printed circuit board retainer to a passthroughpartition wherein the printed circuit board extends through thepassthrough partition; configuring the assembled bulkhead passthroughconnector to be secured to a bulkhead wherein the passthrough partitionseparates the first side of the bulkhead and the second side of thebulkhead and the printed circuit board extends from the first side ofthe bulkhead to the second side of the bulkhead in order to transmitelectric signals; and attaching the bulkhead to the electronic valveactuator wherein the first side of the bulkhead or the second side ofthe bulkhead cooperates with the electronic valve actuator, allowing theprinted circuit board to interface with a gear key encoder and the gearkey encoder controls the motor of the electronic valve actuator, drivinga motor drive shaft to actuate the valve.